Blow molded headliner

ABSTRACT

An automotive headliner assembly includes a substrate that is configured to mount to a vehicle in a position generally covering a lower surface of a passenger compartment roof. Cavities are formed into the substrate between the upper substrate surface and the lower substrate surface to provide receptacles for electrical wiring, fiber optic cabling, EA foam and the like or to form a duct for directing air flow. Each of the cavities is integrally formed in the substrate. A foam layer is adhered to a lower surface of the substrate and the decorative cover is adhered to a lower surface of the foam layer. The headliner is constructed by first extruding molten parison into a blow mold shaped to complement the desired exterior contours of the headliner substrate to be formed. The cavities are then formed in the molten parison by inserting at least one blow pin into the parison and injecting pressurized gas. For those cavities that are configured to hold energy-absorbing foam, foam is provided within each such cavity by inserting a nozzle into the cavities and filling the cavities with the foam.

This application is a division of Ser. No. 09/116,163 filed Jul. 16,1998 U.S. Pat. No. 6,086,145.

TECHNICAL FIELD

This invention relates generally to an automotive headliner having anintegral cavity and a method for making such a headliner.

INVENTION BACKGROUND

Inside vehicle roof constructions sometimes include laminatedheadliners. Such headliners are used in many types of vehicles includingpassenger cars, vans, buses, trucks, trains and airplanes. Headlinersare incorporated into vehicle roof constructions for a variety ofreasons including aesthetics, sound absorption, energy absorption, andconcealment of electrical wiring harnesses and air vents.

Materials currently used in headliner construction includeparticleboard, fiberboard, plastic board, scrim, fabric, plastic,various foams and resin-bonded chopped glass fiber. In some headliners,layers of these materials are joined together into a single laminatestructure using lay-up-molding techniques. For example, some headlinersare constructed using glass reinforced polyester resin laminated to arigid urethane foam layer and covered by a soft urethane foam backedfabric. Other headliners are thermoformed laminates that include apolystyrene foam layer sandwiched between layers of kraft paper orpolymer film material and covered with soft polyurethane foam-backedfabric. Some constructions eliminate the paper or polymer film coveringfrom such laminates and substitute a non-woven fabric batt adhered toone or both sides of the foam layer. Still other headliners, rather thanbeing layered constructions, are simply molded from a single layer of acomposition such as fiberglass reinforced polyester resin.

Headliners are typically contoured to conform to the dimensions of thevehicle roof structure they are intended to cover. Their dimensions arealso contoured to flow into adjacent interior vehicle trim panels,pillars and other such structures to present a pleasing, finishedaesthetic appearance to vehicle occupants.

In U.S. Pat. No. 5,340,425, issued Aug. 23, 1994 to Strapazzini, theinventor proposes that headliners could be constructed to incorporatemolded-in inserts of various kinds to include sound proofing material ordecorative carpet-like material.

In addition, it is known in the art for headliner assemblies to includeone or more electrical wiring harnesses. The harnesses are attached tohidden upper surfaces of such headliner assemblies using fasteners thatroute the wiring harnesses to a variety of sockets for the electricalaccessories mounted to the headliners. The headliner assemblies are thenmounted to a vehicle roof and an interconnecting wire harness in thevehicle is connected to one or more of the harnesses attached to theheadliner assembly.

For example, U.S. Pat. No. 5,309,634, issued May 10, 1994 to Van Orderet al. and assigned to Prince Corporation, discloses a headliner or roofpanel that includes a variety of clips and mounts for wiring, lamps andthe like. The Van Order et al. patent describes the roof panel as beingformable from any one or more of a number of molded polymeric materials.The patent also discloses that the molded roof panel can be covered by afoam layer and a decorative outer cover. However, neither the Van Orderet al. patent nor the Strapazzini patent disclose a headliner or amethod for making a headliner with structures that can direct airflow inor out of a vehicle interior and/or support energy absorbing materials.

British patent application no. 1,115,212, published May 29, 1968,discloses an automotive headliner with a lower cushioning layer spacedfrom an upper roof covering by longitudinal ribs. The cushioning layer,roof covering and ribs define air ducts for supplying air to andremoving air from the vehicle interior. According to the Britishapplication the ribs may be integrally formed with the cushioning layerbut must be assembled to the roof covering in a separate step.

It is also known in the art for headliner assemblies to include a ductthat is disposed on an upper surface of the headliners. Outlet registersare mounted in holes formed in the headliner at spaced locations. Theduct directs airflow from a vehicle heating, ventilation and airconditioning system into a vehicle passenger compartment through thethree air outlet registers. In such systems, the duct is formedseparately from the headliner and is fastened to the headliner duringmanufacturing by such means as gluing.

It is also known to use blow-molded materials to form certain parts ofinstrument panels. An example of such a use is shown in U.S. Pat. No.5,527,581, issued Jun. 18, 1996 to Sugawara et al. and assigned to aJapanese supplier of blow moldable materials. The instrument paneldisclosed in the Sugawara et al. patent includes a core part havingblow-molded sections that are formed from a parison. The parison isfixtured in a blow mold to form integral cavities in the form of airflowducts in the instrument panel.

What is needed is a headliner configured to support such items as energyabsorbing foam, passenger compartment airflow, and electrical wiringwhile presenting a continuous, unencumbered aesthetic appearance tovehicle occupants. What is also needed is a cost-effective method formaking such a headliner.

INVENTION SUMMARY

In accordance with this invention an automotive headliner assembly isprovided that includes a cavity formed into the substrate between upperand lower substrate surfaces to provide a receptacle for wiring, foamand the like or to provide a duct for directing airflow. The headlinerassembly is configured to line the roof of the passenger compartment ofa vehicle. The headliner assembly comprises a unitary substrateconfigured to be mounted to a vehicle in a position generally covering alower surface of a passenger compartment roof. The lower substratesurface is disposed opposite the upper substrate surface. The substratecomprises a moldable material. A decorative cover may be supported onthe lower substrate surface.

According to another aspect of the invention, the cavity comprises anair duct and the headliner includes an air inlet opening positioned toreceive air from a vehicle air handling system. An air outlet opening isspaced from the air inlet opening and disposed in an underside surfaceof the headliner assembly to direct air from the vehicle air handlingsystem into the passenger compartment. The air duct extends between andconnects the air inlet opening and the air outlet opening to providegaseous communication between the air inlet opening and the air outletopening. Because the air duct is formed into the headliner substrate,the headliner assembly includes fewer parts and its fabrication isgreatly simplified.

According to another aspect of the invention a directional air outletregister is disposed in the air outlet opening.

According to another aspect of the invention the cavity comprises anelongated conduit and the headliner includes a cable inlet openingdisposed adjacent a peripheral edge of the headliner assembly to receiveelectrical or fiber optic cabling from a vehicle electrical or fiberoptic system. A cable outlet opening is spaced from the cable inletopening and is disposed adjacent a fixture supported on the headlinerassembly to allow an end of the cable to be connected to the fixture.The cable conduit extends between and provides a channel between thecable inlet opening and the cable outlet opening.

According to another aspect of the invention, foam is disposed withinthe cavity. The cavity may include an inner wall that envelops the foam.The foam may be energy-absorbing foam to enhance the ability of thecavity to absorb passenger head impact forces. The foam may be anacoustic energy-absorbing foam to reduce noise levels within thepassenger compartment.

According to another aspect of the invention additional foam-filledcavities are disposed in an array at spaced locations where passengerhead impact is likely to occur if passengers are subjected to suddenvertical acceleration components.

According to another aspect of the invention the cavity is integrallyformed in the substrate.

According to another aspect of the invention, a decorative outer coveris disposed on a lower surface of the substrate. A foam layer may beincluded between the lower surface of the substrate and the decorativeouter cover.

According to another aspect of the invention, a method is provided forconstructing a headliner. According to the method a blow mold isprovided, the blow mold having a contoured portion shaped to complementthe desired exterior contours of the headliner substrate to be formed.The contoured portion includes an enlarged region corresponding to adesired cavity position in the substrate to be formed. A molten parisonis then extruded into the hollow portion of the blow mold and theparison is expanded into conforming contact with the contoured portionof the blow mold by injecting gas into the molten parison. The moltenparison is then allowed to harden into the headliner substrate and thesubstrate is removed from the blow mold.

According to another aspect of the inventive method, the molten parisonis provided between open halves of a two-piece blow mold. The two blowmold halves are closed together around the molten parison before fullyexpanding the molten parison.

According to another aspect of the inventive method, a layer of foam isprovided on a lower surface of the substrate and a layer of covermaterial is provided on a lower surface of the foam.

According to another aspect of the inventive method, foam is providedwithin the cavity.

According to another aspect of the inventive method, foam is providedwithin the cavity by first inserting one end of an injection nozzle.Foam is then injected into the cavity through the nozzle and the nozzleis withdrawn from the cavity.

According to another aspect of the inventive method, the molten parisonis extruded.

According to another aspect of the inventive method, the molten parisonis expanded by inserting a blow pin into the molten parison, injectingthe gas into the parison through the blow pin and removing the blow pinfrom the parison.

BRIEF DESCRIPTION OF THE DRAWINGS

To better understand and appreciate the invention, refer to thefollowing detailed description in connection with the accompanyingdrawings:

FIG. 1 is a perspective view of a headliner assembly constructedaccording to the present invention;

FIG. 2 is a top view of the headliner assembly of FIG. 1;

FIG. 3 is a cross-sectional side view of the headliner assembly of FIG.1 taken along line 3—3 in FIG. 2;

FIG. 3A is an enlarged view of the region bounded by circle 3A in FIG.3;

FIG. 4 is a cross-sectional side view of a blow-mold with a parisonextrusion die injecting a molten parison between halves of the die inaccordance with the method of the present invention; and

FIG. 5 is a cross-sectional side view of the blow mold of FIG. 4 with ablow pin injecting gas into the molten parison in accordance with themethod of the present invention.

PREFERRED EMBODIMENT DESCRIPTION

A headliner assembly for lining the roof of the passenger compartment ofa vehicle is generally shown at 10 in FIGS. 1-3. The headliner assembly10 includes a unitary substrate, generally indicated at 12 in FIGS. 1-3,that is configured to mount to a vehicle in a position generallycovering a lower surface of a passenger compartment roof (not shown).The substrate 12 includes an upper substrate surface shown at 14 inFIGS. 1-3 and a lower substrate surface shown at 16 in FIG. 3. The lowersubstrate surface 16 is disposed opposite the upper substrate surface14. The substrate 12 may be made of any suitable moldable material toinclude various plastics or fiberglass reinforced polyester resin.

A decorative cover, shown at 18 in FIG. 3, is supported on the lowersubstrate surface 16. The decorative cover 18 may be in the form of afabric or solid layer of any suitable material.

Cavities, shown at 20, 22 and 24 in FIG. 3 are formed into the substrate12 between the upper substrate surface 14 and the lower substratesurface 16. One of the cavities, shown at 20 in FIG. 3 is defined by anelongated receptacle or conduit, shown at 26 in FIGS. 1-3. The conduit26 is configured to support electrical wiring or fiber optic cabling.

Two of the cavities, shown at 22 in FIG. 3, are defined by generallyrectangular pockets, shown at 28 in FIGS. 1-3. As best shown in FIG. 3,the pockets 28 are configured to hold energy absorbing foam 34. In otherembodiments, the pockets 28 may be filled with acoustic energy or soundabsorbing foam or other energy-absorbing materials or structures. Instill other embodiments, the pockets 28 may be configured to absorbpassenger head impact energy without the aid of foam filling.

The largest of the cavities, shown at 24 in FIG. 4, is defined by acontoured duct shown at 30 in FIGS. 1-3. The duct 30 is configured todirect airflow into a vehicle passenger compartment.

Each of the cavities 20, 22, 24 is preferably integrally formed in thesubstrate 12. In other words, the conduit 26, compartments 28 and duct30 are integrally formed with the substrate 12 as a single unitarypiece.

A foam layer, shown at 32 in FIG. 3, is preferably disposed on a lowersurface of the substrate 12 and the decorative outer cover 18 isdisposed on a lower surface of the foam layer 32. The foam layer 32 anddecorative outer cover 18 may be fastened in place by adhesives or anyother suitable means.

Cavity 24 and air duct 30 protrude upward from the substrate 12 and haverounded contours to facilitate airflow. At one end of the air duct 30the headliner assembly 10 includes an air inlet opening shown at 36 inFIGS. 1 and 2. The air inlet opening 36 is disposed adjacent aperipheral edge 38 of the headliner assembly 10 and is configured toreceive air into the air duct 30 from a vehicle air handling system,e.g., a heating, ventilating and air conditioning (HVAC) system (notshown). Three air outlet openings are shown at 40 in FIGS. 2 and 3. Theair outlet openings 40 are spaced from each other and are spaced fromthe air inlet opening 36. The air outlet openings 40 are disposed in atriangular array and extend through a thickness of the headlinerassembly 10. The air outlet openings 40 direct air from the vehicle airhandling (HVAC) system into the passenger compartment. The air duct 30extends between and connects the air inlet opening 36 and the air outletopenings 40 to provide gaseous communication between the air inletopening 36 and the air outlet openings 40.

A directional air outlet register, shown at 44 in FIG. 3, is rotatablymounted within each air outlet opening 40 and protrudes from anunderside surface 42 of the headliner assembly 10. The directional airoutlet registers 44 allow passengers to direct air to various parts ofthe passenger compartment.

Similar to the air duct 30, the conduit 26 protrudes upward from thesubstrate 12. The conduit 26 is configured to support wires or cables 46that will conduct electricity, light, or other forms of electromagneticradiation to various points in the headliner assembly 10. Morespecifically, the conduit 26 defines an elongated tube. Thecross-sectional shape of the conduit 26 may be any suitable shape forholding cables 46. The headliner assembly 10 includes a cable inletopening 48 at one end of the conduit 26 and disposed adjacent theperipheral edge 38 of the headliner assembly 10. The cable inlet opening48 is positioned to receive cables 46 leading to the vehicle roof from avehicle electrical or fiber optic system.

Two cable outlet openings, shown at 50 in FIGS. 1-3 are spaced from thecable inlet opening 48. The cable outlet openings 50 s are disposedadjacent respective electrical or fiber-optic light fixtures shown at 52in FIGS. 1-3. In the present embodiment, the fixtures 52 are electricaldome lights. However, in other embodiments, each fixture 52 may include,for example, a fiber optic dome or indicator light. Each fixture 52 mayalso include a roof-mounted electronic accessory such as a radio,television, computer monitor, tape deck or CD-player that is supportedon or adjacent the headliner assembly 10. The cable outlet openings 50are disposed adjacent such fixtures 52 to allow the electrical or fiberoptic cables to be connected to the fixtures 52. The cable conduit 26extends between and connects the cable inlet opening 48 and the cableoutlet openings 50.

The pockets 28 support energy absorbing foam 34 in strategic locationsin the substrate 12. Each pocket 28 includes an inner wall 54 thatenvelops and seals the energy-absorbing foam 34 within the pocket 28.The foam-filled cavities 22 of the pockets 28 are disposed in an arrayat spaced locations where passenger head impact is likely to occur ifpassengers are subjected to sudden vertical acceleration components. Thetwo pockets 28 of the present embodiment are disposed directly above theseating locations for the driver and the front seat passenger as shownin FIGS. 1-3.

The headliner assembly 10 may be constructed according to the presentinvention by first fabricating a two-piece clamshell-type blow mold asis generally indicated at 56 in FIGS. 4 and 5. The mold 56 is fabricatedto include a hollow portion, shown at 58 in FIGS. 4 and 5, for receivingmolten parison 60 and shaping exterior contours of the headlinersubstrate 12 to be formed. In fabricating the mold 56, the hollowportion 58 of the mold 56 is shaped to complement desired exteriorcontours of the headliner substrate 12 to be formed. As shown in FIGS. 4and 5, the hollow portion 58 is also configured to include enlargedregions 62, 64, 66 corresponding to respective cavities 20, 22, 24 to beformed in the substrate 12. An additional hollow portion forms an airpassage, shown at 70 in FIGS. 4 and 5, at one end of the mold 56 whenthe two halves are joined together. The air passage is configured toreceive an air injector such as a blow pin 74. The air passage 70branches to the enlarged regions 62, 64, 66 of the hollow portion 58 ofthe mold 56 to allow air to be injected into each of the enlargedregions 62, 64, 66 from the air injector.

Once the mold 56 has been fabricated, a molten parison 60 is extrudeddownward between the open mold halves and into the hollow portion 58within the blow mold 56. As shown in FIG. 4, a parison extrusion die 72extrudes the parison 60 in the form of an oblong, hollow tube. The moldhalves are then closed together around the tubular parison 60, pinchingtogether opposed walls 63, 65 of parison along outer boundaries of theenlarged regions 62, 64, 66. Pressurized gas is then injected into ahollow center region 67 of the molten tubular parison 60 causing theparison 60 to expand within the enlarged regions 62, 64, 66 of thehollow portion 58 of the mold 56. The pressurized gas also causes theparison 60 to expand within the gas passage 70, conforming to thecontours of the gas passage 70 as shown at 80 in FIGS. 1-3A. After thecavities 20, 22, 24 have been formed in the parison 60, the blow pin 74may be removed from the parison 60.

The parison 60 is then allowed to harden into the desired shape of theheadliner substrate 12. The blow mold 56 is then opened and theheadliner substrate 12 is removed. Following hardening and removal ofthe headliner substrate 12, the foam layer 32 is adhesively applied tothe substrate lower surface 16 and the decorative outer cover 18 or skinis adhesively applied to the lower surface of the foam layer 32.Alternatively, the decorative outer cover 18 and foam layer 32 may beplaced in the blow mold 56 before molding and integrally joined duringmolding. As another alternative, the outer cover 18 and foam layer 32may be coextruded at the same time as a multi-layered parison.

As shown in FIG. 3, foam 34 is provided within the pocket cavities 22 byinserting nozzle portions 76 of one or more foaming machines into thepocket cavities 22 and filling the pocket cavities 22 with the foam 34.Preferably, the foam is urethane foam produced via a reaction injectionmolding process. This may be accomplished either before or after theheadliner substrate 12 is removed from the mold 56. Foam injection mayalso occur instead of gas injection in forming the pocket cavities 22rather than after gas injection and pocket cavity formation. After foaminjection is complete the foam injection nozzles 76 are then withdrawnfrom the pocket cavities 22 and the foam 34 allowed to cure.

The description and drawings illustratively set forth my presentlypreferred invention embodiment. I intend the description and drawings todescribe this embodiment and not to limit the scope of the invention.Obviously, it is possible to modify this embodiment while remainingwithin the scope of the following claims. Therefore, within the scope ofthe claims, one may practice the invention otherwise than as thedescription and drawings specifically show and describe.

I claim:
 1. A method for making a headliner comprising a substrateconfigured to be mounted to a vehicle in a position at least partiallycovering a lower surface of a passenger compartment roof, the substratecomprising an upper substrate surface and a lower substrate surfacedisposed opposite the upper substrate surface, and a substrateperipheral edge, the substrate comprising a moldable material, and acavity formed into the substrate between the upper substrate surface andthe lower substrate surface; the method including the steps of:providing a blow mold having first and second opposing wall surfacescontoured to complement the exterior contours of the headliner substrateto be formed, including an enlarged region corresponding to a cavityposition in the substrate to be formed; providing a molten parison intothe blow mold between said first and second opposing wall surfaces, saidmolten parison being formed with opposed walls; expanding the moltenparison with opposed walls into conforming contact with said first andsecond wall surfaces of the blow mold by injecting gas into the moltenparison; forming a headliner substrate having a cavity formed within bypinching together said first and second opposed walls of said parison ata location within said peripheral edge; allowing the molten parison toharden; removing the headliner substrate from the blow mold; andproviding a layer of foam on a lower surface of the substrate andproviding a layer of cover material on the lower surface of the foam. 2.The method of claim 1 in which the step of forming the headlinersubstrate by injecting gas into the molten parison and expanding themolten parison includes the additional steps of: inserting a blow pininto the molten parison; injecting the gas into the parison through theblow pin; and removing the blow pin from the parison.
 3. The method ofclaim 1 including the additional step of providing the cavity with oneinlet opening.
 4. The method of claim 3 in which the step of providingthe cavity with at least one inlet opening includes providing an airinlet opening.
 5. The method of claim 4 in which the step of providingthe cavity with at least one inlet opening includes providing a cableinlet opening.
 6. The method of claim 1 including the additional step ofproviding the cavity with at least one outlet opening.
 7. The method ofclaim 6 in which the step of providing the cavity with at least oneoutlet opening including providing an air outlet opening.
 8. The methodof claim 1 in which the step of providing the cavity with at least oneoutlet opening includes providing a cable outlet opening.
 9. The methodof claim 1 wherein said step of providing a layer of foam on said lowersurface of the substrate and providing a layer of cover material on thelower surface of said foam comprises supplying a cover material thatincludes a layer of foam on said cover material.
 10. The method of claim1 including the step of providing foam within said cavity prior toremoving said headliner substrate from said blow mold.
 11. The method ofclaim 1 wherein the step of providing said molten parison comprisesextruding said molten parison.
 12. The method of claim 11 wherein saidcover material and foam is coextruded with said parison.
 13. The methodof claim 1 wherein said step of providing a layer of foam on said lowersurface of the substrate and providing a layer of cover material on thelower surface of said foam comprises placing said cover material andfoam in said blow mold and joining said foam to said parison when saidparison is expanded in said blow mold.
 14. A method for making aheadliner comprising a substrate configured to be mounted to a vehiclein a position at least partially covering a lower surface of a passengercompartment roof, the substrate comprising an upper substrate surfaceand a lower substrate surface disposed opposite the upper substratesurface, and a substrate peripheral edge, the substrate comprising amoldable material, and a cavity formed into the substrate between theupper substrate surface and the lower substrate surface; the methodincluding the steps of: providing a blow mold having first and secondopposing wall surfaces contoured to complement the exterior contours ofthe headliner substrate to be formed, including an enlarged regioncorresponding to a cavity position in the substrate to be formed;providing a molten parison into the blow mold between said first andsecond opposing wall surfaces, said molten parison being formed withopposed walls; expanding the molten parison with opposed walls intoconforming contact with said first and second wall surfaces of the blowmold by injecting gas into the molten parison; forming a headlinersubstrate having a cavity formed within by pinching together said firstand second opposed walls of said parison at a location within saidperipheral edge; allowing the molten parison to harden; removing theheadliner substrate from the blow mold; and providing foam within saidcavity.
 15. The method of claim 14 in which the step of providing a foamincludes the steps of: inserting one end of a nozzle into the cavity;injecting the foam into the cavity through the nozzle; and withdrawingthe nozzle from the cavity.